Overview

The 3500 system is the world-leader at detecting and preventing both missed-trips and false-trips in rotating machinery. With over 85,000 installed worldwide, it provides automatic protection value by tripping monitored machines to prevent expensive damage when needed.

The 3500 system also protects your machines and processes against false-trips that could bring your operation down for no reason, resulting in a costly outage or loss of production.

When connected with our System 1 software, it also provides continuous condition monitoring information for use in a proactive maintenance program.

The 3500 system incorporates the industry’s most extensive selection of machinery measurement parameters combined with software configuration for virtually all machinery monitoring scenarios.

Sensors

Our Commitment

Bently Nevada has been synonymous with machinery protection and condition monitoring for more than 60 years. Our network of global experts is dedicated to helping customers solve some of their toughest challenges. From refineries and petrochemical plants to hydroelectric facilities and wind farms, Bently Nevada asset condition monitoring offers trusted and proven vibration monitoring equipment and a comprehensive services portfolio to help improve the reliability and performance of production assets like turbines, compressors, motors, generators, and everything in between.

Behind every suite of great products is a team of great people, and the Bently Nevada team is one of the most experienced in the industry. That experience translates into high-quality, flexible and scalable solutions coupled with a dedicated services team focused on providing proactive, consistent support throughout the lifecycle of your operations. 

3500 Machinery Protection System Product Overview

3500 Machinery Protection System Product Overview
3500 Machinery Protection System Product Features

3500 Series protection and condition monitoring system is a flexible, scalable platform for continuous, online monitoring of your most critical machinery as well as all other machine assets used in plant-wide processes, all available in a single comprehensive system. 

  • Reliable and Compliant
  • Compatible and Flexible
  • Communicates with System 1
  • Available Options
  • Safety Certified
3500 Machinery Protection System Displays

The 3500/94M VGA Touchscreen Display Module with color Touch Screen and I/O module displays vital 3500 data at the machine or in the control room. The VGA features 3500 vibration levels, system and alarm event lists along with module, channel and alarm data and nine custom display options. Pre-built “custom” screens for Direct, 1X, Gap, and alarms with no need to configure make set up easy. There 2 sizes available (10” and 15”) and you can you can view data from up to four separate 3500 racks at just one display. There are also mount options for the display module, including the hinged and latched Face Mount. Hazardous Area certifications are available for the displays.

3500 Machinery Protection System Speed Monitors

The TACH100 Digital Tachometer can serve as a stand-alone speed indicator or in conjunction with any permanently installed monitoring system as a remote speed indicator. The compact unit contains its own power supply, which is convenient when a permanent monitoring system is located at a distance or proximity to the machine is needed to indicate speed. The Digital Tachometer provides a local display indicating machine speed on the machine deck.  When double-hearing protection is required, the Digital Tachometer provides a visual indication. Wires can connect in parallel with Keyphasor Proximity Probe input on the monitor rack or directly to the Keyphasor† Proximity Probe. The TACH100 accepts signal and common wires from externally-powered Keyphasor Proximity Probe.

Our 3500/25 Keyphasor Module provides phase reference information in a 3500 rack (you can employ up to four Keyphasors per 3500 rack), enabling advanced machinery diagnostics. It receives input signals from proximity probes or magnetic pickups and converts the once-per-turn or multiple-event-per-turn pulse signals to a precise digital timing measurement. This allows your 3500 system to measure machine speed and vector parameters such as 1X vibration amplitude and phase that are key in determining vital machine behaviors. The Keyphasor measurement is also an integral part of the Bently Nevada† Turbine Supervisory Instrumentation (TSI) suite of sensors specifically for steam turbines. The 3500 System is available as a SIL 2-rated system and with multiple Hazardous Area and country-specific approvals available to tackle any environment.

Our 3500/50M Tachometer Module features 2 channels which accept input from Proximitor probes or magnetic pickups to measure shaft rotating speed, rotor acceleration, or reverse rotation. The 3500/50M Tachometer conditions the inputs and compares the conditioned signals with user-programmable set points that can drive alarms and relay logic in the 3500 relay modules. Alarm options offered with 3500 Rack Configuration software include Speed Band, Zero Speed, Rotor Acceleration and Reverse Rotation. The Keyphasor and speed measurements are also an integral part of the Bently Nevada Turbine Supervisory Instrumentation (TSI) suite of sensors for steam turbines. The 3500 System is available as a SIL 2 rated system and with multiple Hazardous Area and country-specific approvals available. External terminations and internal barrier versions are also available. You should note that the 3500/50M is not designed for Overspeed Detection.

3500 Machinery Protection System Relay Monitors

The 3500/32M 4-Channel Relay Module offers four relay outputs with a highly-configurable relay logic interface. Each of the four outputs can be independently programmed to enable voting by configuring the Alarm Drive Logic for each relay. All channels within the 3500 Machinery Protection System are available to drive complex logic using Not OK status along with Alert and Danger setpoints within the 3500/32M. The 3500/32M offers an easy-to-use interface for highly configurable AND/OR logic combinations and includes ‘Normal’ and ‘True’ and voting options as well as a latching relay by-channel option.

3500/33 16-Channel Relay Module offers 16 relay outputs with a highly-configurable relay logic interface. Each of the sixteen outputs can be independently programmed to enable voting by configuring the Alarm Drive Logic for each relay. All channels within the 3500 Machinery Protection System are available to drive complex logic using Not OK status along with Alert and Danger setpoints within the 3500/33. The 3500/33 offers an easy-to-use interface for highly configurable AND/OR logic combinations and includes ‘Normal’ and ‘True’ and voting options as well as a latching relay by-channel option.

3500 Machinery Protection System Vibration Input Monitors

3500/40M Proximitor Monitor accepts input from Bently Nevada 3300XL series of Proximitor and seismic transducers conditions the signal to provide various vibration and position measurements, and compares the conditioned signals with user-programmable setpoints that can drive alarms and relay logic in the 3500 relay modules. External terminations and internal barrier versions are also available. The 3300XL Proximitor measurements are an integral part of the Bently Nevada Turbine Supervisory Instrumentation (TSI) suite of sensors for steam turbines. Each channel can be programmed using the 3500 Rack Configuration Software to protect machinery and monitor conditions for Radial Vibration, Thrust Position, Differential Expansion, Eccentricity, Acceleration, Velocity, Shaft Absolute, and Circular Acceptance Region parameters. The 3500 System is available as a SIL 2 rated system and with multiple Hazardous Area and country-specific approvals available.

Bently Nevada’s 3500/42M Proximitor/Seismic Monitor offers four programmable channels for the 3500 system, accepting input from Proximitors and seismic transducers. The 3500/42M then conditions the signal to provide various vibration and position measurements and compares the conditioned signals with user-programmable alarms. Additionally, each channel can be programmed using the 3500 Rack Configuration Software to protect machinery and monitor conditions for Radial Vibration, Thrust Position, Differential Expansion, Eccentricity, Acceleration, Velocity, Shaft Absolute, and Circular Acceptance Region parameters.

The 3500/44M Aeroderivative Gas Turbine Monitor is a four channel Aeroderivative Gas Turbine (GT) Vibration Monitor for the 3500 system. The Vibration Monitor accepts four channels of vibration. Each channel pair can apply its own tracking filter based on up to four different Keyphasor inputs from the 3500 rack. The monitor processes signals from the Velomitor† and the accelerometer, filters the measurements, allows Signal Integration, and produces 1X Vibration Tracking and Band-pass Vibration, which is very useful for gas turbine applications. The Vibration Monitor meets the gas turbine manufacturing requirements of Baker Hughes, Rolls Royce, United Technologies and other OEMs.

Our 3500/46M Hydro Monitor is specifically designed to protect and monitor hydro turbine generators. The 3500/46M Processes signals from Proximitors, seismic, dynamic pressure, and air gap sensors. Discreet Input contacts can identify machinery modes such as Rough Load Zone and automate data acquisition and alarms. External terminations are also available. The 3500/46M Hydro Monitor also conditions input and compares signals with alarm setpoints for Hydro Radial Vibration (RV), Hydro Air Gap, Hydro Velocity, Hydro Acceleration, Hydro Thrust, Hydro Stator End Winding (SEW) Vibration; and Dynamic Pressure. Multimode settings are available for all available channel types.

3500 Machinery Protection System Position Monitor

The 3500/45 Position Monitor processes signals from the Bently Nevada 3300XL series of Proximitor transducers, Rotary Position Transducers (RPTs), and AC and DC Linear Variable Differential Transformers (LVDTs). The 3500/45 conditions the input and compares the conditioned signals with user-programmable alarms for Axial (thrust) Position, Differential Expansion (single ramp, dual ramp, or complementary), Case Expansion, and Valve Position. These key measurements are an integral part of the Bently Nevada Turbine Supervisory Instrumentation (TSI) suite of sensors for steam turbines.

3500 Machinery Protection System Temperature Monitors

The six-channel 3500/60 (without recorders) processes the signals from RTDs (resistance temperature detectors) and TCs (thermocouples). The 3500/60 is capable of monitoring temperature or temperature differentials and is typically used for radial bearing or thrust bearing metal temperature in accordance with API670, but can also be used for key process temperatures such as compressor suction and discharge temperatures, steam temperature, motor stator temperatures, among others. The 3500/60 conditions the inputs and compares the conditioned signals with user-programmable setpoints that can drive alarms and relay logic in the 3500 relay modules. External terminations and internal barrier versions are also available. The 3500/60 and 3500/61 provide identical functionality, with the 3500/61 offering additional 4-20mA recorder outputs for each of its six channels. The TC-isolated version provides 250 Vdc of channel-to-channel isolation that is sometimes required for use with high speed mag pickup applications.

Our six-channel 3500/61 (with recorders) processes the signals from RTDs (resistance temperature detectors) and TCs (thermocouples). The 3500/61 is capable of monitoring temperature or temperature differentials and is typically used for radial bearing or thrust bearing metal temperature in accordance with API670, but can also be used for key process temperatures such as compressor suction and discharge temperatures, steam temperature, motor stator temperatures, among others. The 3500/61 conditions the inputs and compares the conditioned signals with user-programmable setpoints that can drive alarms and relay logic in the 3500 relay modules. External terminations and internal barrier versions are also available. The 3500/60 and 3500/61 provide identical functionality, with the 3500/61 offering additional 4-20mA recorder outputs for each of its six channels while the 3500/60 does not. The TC-isolated version provides 250 Vdc of channel-to-channel isolation that is sometimes required for use with high speed mag pickup applications.

Bently Nevada’s 3500/65 16-Channel Temperature Monitor processes the signals from RTDs (resistance temperature detectors) and TCs (thermocouples). The 3500/65 is capable of monitoring temperature or temperature differentials and is typically used for radial bearing or thrust bearing metal temperature in accordance with API670, but can also be used for key process temperatures such as compressor suction and discharge temperatures, steam temperature, motor stator temperatures, among others. The 3500/65 conditions the inputs and compares the conditioned signals with user-programmable setpoints that can drive alarms and relay logic in the 3500 relay modules. The 3500/65 accepts isolated tip thermocouples, 3-wire RTD, 4-wire RTD, or a combination of isolated TC and RTD inputs. External termination blocks are also available. If recorder outputs are required, the 3500/61 six-channel temperature monitor provides additional 4-20mA recorder outputs for each of its six channels.

3500 Machinery Protection System Process & Pressure Monitors

Our six-channel 3500/62 Process Variable Monitor accepts transmitter 4 to 20 mA current inputs or -10 Vdc to +10 Vdc voltage sensor inputs, and then conditions the input and compares the conditioned signals with user-programmable alarm setpoints that can drive alarms and relay logic in the 3500 relay modules. The 3500/62 can also be used for key process measurements such as fluid pressure, compressor suction and discharge pressures, steam pressure, motor current, flow, Megawatts and virtually any other process variable that can then be correlated via vibration.

The four-channel 3500/64 Dynamic Pressure Monitor accepts input from gas turbine dynamic pressure (combustion) transducers and uses this input to drive alarms. The monitor produces band-passed dynamic pressure measured variables. Programmable corner frequencies for the bandpass filter and an additional notch filter can be adjusted as needed. A typical application identifies and tracks gas turbine combustor instabilities. Dynamic Pressure sensors use Bently Nevada charge amplifiers 350500 or 86517 and can integrate a multitude of common dynamic pressure sensors, including the CP series sensors. Additionally, the 3500/64 is available with multiple Hazardous Area and country-specific approvals to tackle any environment.

3500 Machinery Protection System Recip Monitors

Bently Nevada’s 4-channel 3500/70M Recip Impulse/Velocity Monitor:  

  • Receives input on both acceleration and velocity from seismic transducers such as the Bently Nevada 330400, 330425 and Velomitor CT.
  • Conditions signals to receive vibration measurements and compares the measured variables to user-programmable alarms.
  • Sets up Impulse Acceleration, Acceleration 2, Recip Velocity and Low Frequency Recip Velocity channel functions as needed.

Our 4-channel 3500/72 Recip Rod Position Monitor processes signals from Bently Nevada Proximitor transducers to create measurements optimized for piston rod position monitoring. Provides vital insight into the condition of reciprocating compressors. Additionally, each channel can be programmed to perform rod position measurement, rod drop measurement and hyper-compressor measurement.

The 4-channel 3500/77M Recip Cylinder Pressure Monitor:  

  • Optimizes monitoring - Accepts input from the unique Bently Nevada 165855-approved cylinder pressure transducers to generate a range of measurements optimized for monitoring the condition of a reciprocating compressor in API-618 service.
  • Measures performance and diagnostics - Combined with System 1 software and a multi-event wheel, dynamic pressure-based measurements accommodate compressor thermodynamic performance monitoring and deep diagnostics and malfunction legends used to identify machine failure modes.
  • Offers multiple measurement variables - Measured cylinder operation variables of the 3500/77M include Maximum and Minimum Pressures, Discharge Pressure, Suction Pressure, Compression Ratio, Peak Rod Compression, Peak Rod Tension and Degrees of Rod Reversal.
3500 Machinery Protection System Communication Gateways

The 3500/91M EGD Communication Gateway Integrates process control and other automation systems using both Ethernet TCP/IP and serial (RS232 / RS422 / RS485) communications capabilities. Permits Ethernet communications with 3500 Rack Configuration Software. The 3500/91 also supports proprietary Bently Nevada protocol along with Modicon Modbus and Modbus/TCP protocols.

3500/92 Communication Gateway integrates easily with process control networks and other automation systems using both Ethernet TCP/IP and serial (RS232 / RS422 / RS485) communications capabilities. Permits communications via Modbus using 3500 Rack Configuration Software. The 3500/92 can be configured using the 3500 Rack Configuration software to produce a custom or condensed Modbus map for communications using fixed or configurable registers. All vital rack information including direct vibration, gap, 1X, 2X, Smax, channel statuses, rack status, trip multiply, rack reset, and others can be easily communicated.

3500 Machinery Protection System Isolators & Barriers

3500 Galvanic Isolators - For machinery protection and condition monitoring in a hazardous area with a potentially flammable atmosphere, 3500 Galvanic Isolators provide Intrinsically Safe (IS) interfaces to Bently Nevada transducers. The Isolators come with a safe installation and a safe interface. They also offer accessories such as earth rails and backplanes.

3500 Internal Barriers are Intrinsically Safe interfaces that provide explosion protection for transducer systems connected directly to the 3500 Machinery Protection System. Unlike external barriers, 3500 Internal Barriers integrate with the 3500 System while maintaining the System’s performance.

3500 Machinery Protection System Cabinets & Housings

Bently Nevada Cabinets provide robust protection for all 3500 racks and the infrastructure they require. The cabinets simplify site installation, provide protection for installed instrumentation and facilitate ongoing ease-of-use and maintenance and include instrumentation options.

The 3500/06 Weatherproof Housing protects the 3500 System against adverse environmental conditions such as excessive moisture, dirt, grime and unclean air. An optional purging system protects the rack from outside elements. The housing is available in epoxy-coated steel or 304 stainless steel and as a SIL 2 rated system with multiple Hazardous Area and country-specific approvals.

3500 Machinery Protection System Rack, Supply, TDI

The 3500/15 AC and DC Power Supplies are half-height modules and must be installed in designated slots on the left side of the rack. The 3500 rack can contain one or two power supplies with any combinations of AC and DC. Either supply can power a full rack. 

The 3500/15 AC and DC Power Supplies of the 3500/15 accept a wide range of high or low input voltages and can convert to voltages required by the 3500 modules. They are ideal for Machinery Protection Systems and allow for one power supply or two if needed for back up. With two power supplies installed, the lower slot holds the primary supply and the upper slot holds the redundant supply. 

The 3500/15 Power Supply can supply AC or DC power to the 3500, including the Transient Data Interface (TDI), individual monitor modules and Input/Output (I/O) modules as well as all connected sensors in a Machinery Protection and Condition Monitoring System. Modules can be "hot-swapped” by removing or inserting either of the power supply modules without disrupting the rack.

The 3500/05 System Rack holds all 3500 monitor modules and rack power supplies, allowing modules to communicate with each other, with System 1 software and power supplies to distribute power to each module as needed. The 3500 system rack is an integral part of the Bently Nevada Turbine Supervisory Instrumentation (TSI) suite for steam turbines.  With two sizes (standard 19” and 14”), three flexible mounting formats (rack, bulkhead, and panel), and internal barrier options for hazardous area, you can customize the 3500/05 System Rack to suit your needs. The Rack also has Weatherproof housing available to protect the 3500 System against adverse environment conditions. The 3500 System is available as a SIL 2-rated system, meaning it will provide Intrinsic Safety.

The 3500/22M, also known as the Transient Data Interface Module (or TDI), is the heart of the 3500 rack system.  It allows for configuration of the 3500 rack parameters and serve as the gateway to the System 1 Machinery Condition Monitoring software platform.

The TDI is equipped with a USB port on the front for easy access for configuration, and a 10/100 Ethernet connection on the rear I/O module for communicating with System 1. A rack reset button on the front allows alarm reset with a physical key to lock out configuration changes.

3500 Machinery Protection System Compatible Services

Bently Nevada offers the following services that will support your 3500 monitoring and protection system in keeping your machinery in the best condition.  

  • Hosted Solutions
  • System Maintenance & Availability
  • Machinery Diagnostic Services
  • Machinery Health Audits
  • Bently Performance
  • Advanced Analytics
  • Remote Monitoring & Diagnostics
  • Site Project Management
  • System Integration Engineering
  • Design, Installation, & Commissioning
  • Cyber System Hardening
  • Cyber Asset Risk Assessments
3500 Machinery Protection System Compatible Hardware
3500 Machinery Protection System Compatible Software

The 3500 system works hand in with these software products.  

  • System 1
  • Visualization & Management
  • Analytics
  • Connectivity
  • Maintenance & Support

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